ME MECHANICAL Product Design and Development

UNIVERSITY OF MUMBAI
New M. E. Programme
Programme: M. E. (Mechanical Engineering)
Product Design and Development
(As per Credit Based Semester and Grading System with effect from
the academic year 2014–2015)
Program Structure for
ME (Mechanical Engineering): Product Design and Development
Semester I
Teaching Scheme Credits Assigned
Course (Contact Hours)
Code Course Name Theory Pract. Tut. Theory Pract. Tut. Total
PDC101 Product Design and 04 - - 04 -- -- 04
development - -
PDC102 Quality Concepts in 04 - - 04 -- -- 04
design - -
PDC103 Material in Product 04 - - 04 -- -- 04
Design and Development - -
PDE101X Elective I 04 - - 04 -- -- 04
PDE102X Elective II 04 - -
-- 04 -- -- 04
PDL101 CAD: Solid Modeling Lab -- -
02 - -- 01 -- 01
PDL102 Rapid Prototyping and -
Tooling Lab -- 02 - -- 01 -- 01
Total 20 04 - 20 02 -- 22
- Examination Scheme
Theory
Course Course Name Internal Assessment End Exam. Term Pract.
Code Test1 Test 2 Avg. Sem. Duration Work /oral Total
Exam. (in Hrs)
PDC101 Product Design and 20 20 20 80 03 -- -- 100
development
PDC102 Quality Concepts in 20 20 20 80 03 -- -- 100
design
PDC103 Material in Product 20 20 20 80 03 -- -- 100
Design and Development
PDE101X Elective I 20 20 20 80 03 -- -- 100
PDE102X Elective II 20 20 20 80 03 -- -- 100
PDL101 CAD: Solid Modeling Lab -- -- -- -- -- 25 25 50
PDL102 Rapid Prototyping and
Tooling Lab -- -- -- -- -- 25 25 50
Total -- -- 100 400 -- 50 50 600
Course Code Elective I Course Code Elective II

PDE1011 Computer Aided Product PDE1021 Product and process engineering tools
Development
PDE1012 Reliability Engineering$ PDE1022 Optimization$
PDE1013 Rapid Prototyping and Tooling* PDE1023 Product Packaging
PDE1014 Creativity in design PDE1024 Die Design and Development
* Common for Machine Design, Automobile Engineering and CAD/CAM and Robotics and PDD
$
Common for Machine Design, CAD/CAM and Robotics and PDD
%
Common for Machine Design, Automobile Engineering, CAD/CAM and Robotics, Energy
Engineering and PDD
University of Mumbai, Mechanical Engineering, M E Product Design and Development (New 2014) Page 2/48
Semester II
Course Teaching Credits Assigned

Code Course Name Scheme
(Contact
Theory Pract Tut. Theory Pract. Tut. Total
Hours).
PDC201 Product Life Cycle 04 -- -- 04 -- -- 04
Management
PDC202 Design for X 04 -- -- 04 -- -- 04
PDC203 Applied Ergonomics 04 -- -- 04 -- -- 04
PDE203X Elective III 04 -- -- 04 -- -- 04
PDE204X Elective IV 04 -- -- 04 -- -- 04
PDL203 CAD: Surface -- 02 -- -- 01 -- 01
Modeling Lab
CAE: Computer Aided -- 02 -- -- 01 -- 01
PDL204 Engineering Lab
Total 20 04 20-- 02 -- 22
Examination Scheme
Theory
Course Course Name Internal Assessment End Exam. Term Pract.
Code Test1 Test 2 Avg. Sem. Duration Work /oral Total
Exam. (in Hrs)
PDC201 Product Life Cycle 20 20 20 80 03 - -- 100
Management -
PDC202 Design for X 20 20 20 80 03 - -- 100
PDC203 20 20 20 80 03 -
- -- 100
Applied Ergonomics
-
PDE203X Elective III 20 20 20 80 03 - -- 100
-
PDE204X Elective IV 20 20 20 80 03 - -- 100
-
PDL203 CAD:Surface Modeling -- -- -- -- -- 25 25 50
Lab
CAE: Computer Aided -- -- -- -- -- 25 25 50
PDL204 Engineering Lab
Total -- -- 100 400 -- 50 50 600
Course Code Elective III Course Code Elective IV

PDE2031 Vehicle Design PDE2041 Reverse engineering
PDE2032 Polymeric Material and Processing PDE2042 Product Marketing
PDE2033 Robotics* PDE2043 Composite Material$
PDE2034 Micro Electro Mechanical Systems@ PDE2044 Smart Materials and Applications*
*
Common for Machine Design, Automobile Engineering, CAD/CAM and Robotics and PDD
$
Common for Machine Design and CAD/CAM and Robotics and PDD
@
Common for Machine Design, Automobile Engineering, CAD/CAM and Robotics, Manufacturing
Systems Engineering and PDD
Semester III
Teaching Scheme
Course Credits Assigned
Course Name (Contact Hours)
Code
Theory Pract. Tut. Theory Pract. Tut. Total
PDS301 Seminar -- 06 -- -- 03 -- 03
PDD301 Dissertation I -- 24 -- -- 12 -- 12
Total -- 30 -- -- 15 -- 15
Examination Scheme
Course Theory
Course Name Term Pract.
Code Internal Assessment End Sem. Total
Work / Oral
Test1 Test 2 Avg. Exam.
PDS301 Seminar -- -- -- -- 50 50 100
PDD301 Dissertation I -- -- -- -- 100 -- 100
Total -- -- -- -- 150 50 200
Semester IV
Teaching Scheme
Course Credits Assigned
Course Name (Contact Hours)
Code
Theory Pract. Tut. Theory Pract. Tut. Total
PDD401 Dissertation II -- 30 -- -- 15 -- 15
Total -- 30 -- -- 15 -- 15
Examination Scheme
Course Theory
Course Name Term Pract.
Code Internal Assessment End Sem. Total
Work / Oral
Test1 Test 2 Avg. Exam.
PDD401 Dissertation II -- -- -- -- 100 100 200
Total -- -- -- -- 100 100 200
Note:
o In case of Seminar (PDDS301), 01 Hour / week / student should be
considered for the calculation of load of a teacher
o In case of Dissertation I (PDDD301) and Dissertation II (PDDD401), 02 Hour /
week / student should be considered for the calculation of load of a teacher.
Course Code Course Name Credits
PDC101 PRODUCT DESIGN & DEVELOPMENT 04
Module Detailed Content Hours

1 1.1 Introduction: Classification/ Specifications of Products. 08
1.2 Product life cycle. Product mix.
1.3 Introduction to product design.
1.4 Modern product development process.
1.5 Innovative thinking.
1.6 Morphology of design.
2 2.1 Conceptual Design: Generation, selection & embodiment of concept. 08
2.2 Product architecture.
2.3 Industrial design: process, need.
2.4 Robust Design: Taguchi Designs & DOE.
2.5 Design Optimization
3 3.1 Design for Mfg & Assembly: Methods of designing for Mfg & Assy. 08
3.2 Designs for Maintainability.
3.3 Designs for Environment.
3.4 Product costing.
3.5 Legal factors and social issues. Engg ethics and issues of society related
to design of products.
4 4.1 Value Engineering / Value Analysis. : Definition. Methodology. 08
4.2 Case studies.
4.3 Economic analysis: Qualitative & Quantitative.
5 5.1 Ergonomics / Aesthetics: Gross human autonomy. 08
5.2 Anthropometry.
5.3 Man-Machine interaction.
5.4 Concepts of size and texture, colour .Comfort criteria.
5.5 Psychological & Physiological considerations.
5.6 Creativity Techniques: Creative thinking, conceptualization, brain
storming, primary design, drawing, simulation, detail design.
6 6.1 Concurrent Engg , 08
6.2 Rapid prototyping ,
6.3 Tools for product design – Drafting / Modeling software.
6.4 CAM Interface.
6.5 Patents & IP Acts. Overview, Disclosure preparation.
References:
1. Karl T Ulrich, Steven D Eppinger , “ Product Design & Development.” Tata McGrawhill New
Delhi 2003
2. David G Ullman, “The Mechanical Design Process.” McGrawhill Inc Singapore 1992 N J M
Roozenberg , J Ekels , N F M Roozenberg “ Product Design Fundamentals and Methods .”
John Willey & Sons 1995
3. Kevin Otto & Kristin Wood Product Design: “Techniques in Reverse Engineering and new
Product Development.” 1 / e 2004 , Pearson Education New Delhi
4. L D Miles “Value Engineering.”
5. Hollins B & Pugh S “Successful Product Design.” Butter worths London.
6. Baldwin E N & Neibel B W “Designing for Production.” Edwin Homewood Illinois
7. Jones J C “Design Methods.” Seeds of Human Futures. John Willey New York.
8. Bralla J G “Handbook of Product Design for Manufacture, McGrawhill NewYork.
Assessment:
Internal Assessment: Assessment consists of two tests out of which; one should be
compulsory class test (on minimum 02 Modules) and the other is
either a class test or assignment on live problems or course project.
End Semester Examination: Some guidelines for setting the question papers are as, six questions
to be set each of 20 marks, out of these any four questions to be
attempted by students. Minimum 80% syllabus should be covered
in question papers of end semester examination.
PDC102 QUALITY CONCEPTS IN DESIGN 04
Module Detailed content Hours

1 DESIGN FOR QUALITY 09
Quality Function Deployment -House of Quality-Objectives and functions-
Targets- Stakeholders-Measures and Matrices-Design of Experiments –design
process- Identification of control factors, noise factors, and performance metrics -
developing the experimental plan- experimental design –testing noise factors-
Running the experiments –Conducting the analysis-Selecting and conforming
factor-Set points-reflecting and repeating.
2 FAILURE MODE EFFECT ANALYSIS 09
Basic methods: Refining geometry and layout, general process of product
embodiment- Embodiment checklist- Advanced methods: systems modeling,
mechanical embodiment principles-FMEA method- linking fault states to systems
modeling-Case study- computer monitor stand for a docking station.
3 DESIGN OF EXPERIMENTS 09
Design of experiments-Basic methods- Two factorial experiments-Extended
method reduced tests and fractional experiments, orthogonality, base design
method, higher dimensional fractional factorial design-Statistical analysis of
experiments: Degree of freedom, correlation coefficient, standard error of the
residual t-test, ANOVA-ratio test, other indicators-residual plots, Advanced DOE
method for product testing-Product applications of physical modeling and DOE,
Blender panel display evaluation, coffee grinder experimental optimization-
Taguchi method.
4 STATISTICAL CONSIDERATION 07
Frequency distributions and Histograms- Run charts –stem and leaf plots- Pareto
diagrams-Cause and Effect diagrams-Box plots- Probability distribution-
Statistical Process control–Scatter diagrams –Multivariable charts –Matrix plots
and 3-D plots.
5 RELIABILITY 07
Reliability-Survival and Failure-Series and parallel systems-Mean time between
failure- Weibull distributions(How to calculate or estimate in component level
system level introductory only)
6 DESIGN FOR SIX SIGMA 07
Basis of SIX SIGMA –Project selection for SIX SIGMA- SIX SIGMA problem
solving- SIX SIGMA in service and small organizations - SIX SIGMA and lean
production –Lean SIX SIGMA and services
References:
1. Product Design Techniques in Reverse Engineering and New Product Development, KEVIN
OTTO & KRISTIN WOOD, Pearson Education (LPE), 2001.
2. Product Design and Development, KARL T. ULRICH, STEVEN D. EPPINGER, TATA
McGraw-HILL- 3rd Edition, 2003.
3. The Management and control of Quality-6th edition-James R. Evens, William M Lindsay Pub:
son south-western
4. Fundamentals of Quality control and improvement 2nd edition, AMITAVA MITRA,
Pearson Education Asia, 2002.
Assessment:
End Semester Examination: Some guidelines for setting the question papers are as, six questions to
be set each of 20 marks, out of these any four questions to be
attempted by students. Minimum 80% syllabus should be covered in
question papers of end semester examination.
PDC103 MATERIAL IN PRODUCT DESIGN AND 04
DEVELOPMENT

1 MATERIAL BEHAVIOR AND SELECTION 08
Elastic and Plastic deformation- Mechanism of Plastic deformation-yield stress
and shear strength-Perfect and Real crystals- Effect of strain rate and
temperature on plastic behaviour- Super plasticity- Deformation of non
crystalline materials-
Material selection- Cost and service requirement- Recycling- Selection of
material for mechanical properties- Strength, toughness and fatigue- Material
selection for durability and surface wear and Corrosion resistance- Functional
relation between materials and processing- Manufacturing characteristics of
metals- Material selection charts and other aids material selection for aero, auto
and nuclear application-Structural Product analysis-End
Use behavior – Tooling in product design- Case studies in material selection.
2 PROCESS MODELING AND PRODUCT DESIGN 08
Methods of analysis- Slab, slip line and upper bound solutions- Numerical
methods- Effect of Friction- Contact problem- Basic analysis of process-
Forging, Drawing and sheet metal forming- machining- Turning- modern
materials- micro alloyed and dual
phase steel- High strength low alloy metals- Smart materials- Shape memory
metals- Metallic Glasses- Nano Materials- Metal foams- Properties and
applications for product design.
3 NON METALS AND MANUFACTURING 08

General properties and its importance of polymers-
Thermal and electrical properties mechanical properties- Criteria for selection-
Composite materials- fibers- Boron, glass, carbon, organic- Ceramic and
metallic fibres- - Matrix materials- Polymer, metal and ceramics- properties and
applications- Manufacturing methods of plastic products- Injection and blow
moulding –Rotational moulding-Compression moulding-Transfer moulding-
layering of composites
4 PRODUCT DESIGN AND ASSEMBLY REQUIREMENTS 08
Structural product analysis- End use behaviour- Effect of tooling in product
design-Design for joining and assembling- Design for live hinges- Snap fits,
design of corners,bushes and ribs- Design considerations- New product design-
Methods of decoration-Bonding and cementing techniques- Thermal bonding-
Machining of plastics-Parameters and effect- Case studies in material selection
with relevance to product design and development
5 DEVELOPMENT IN MATERIALS PROCESSING 08
Micro fabrication technologies- Tool for micro fabrication- Diamond and high
speed machining- LIGA micro fabrication process- Multilayer X-ray lithography-
6 Introduction to Smart / Intelligent Materials: 08

Overview of Smart / Intelligent Materials, Primitive Functions of Intelligent
Materials, Intelligence Inherent in Materials, Actuator Materials, Sensing
Technologies, Micro-sensors, Intelligent Systems, Hybrid Smart Materials,
Passive Sensory Smart Structures, Reactive Actuator based Smart
Structures, Active Sensing and Reactive Smart Structures, Smart Skins
References
1. Serope Kalpakjian and Schmid- Manufacturing process for Engineering materials
Pearson- 2005.
2. Paul Degarmo, Black and Kohsher- Materials and processes in Manufacturing-
Wiley Student Edition- 9th Edition- 2005
3. Sami Franssile- Introduction to Micro Fabrication- John Wiley and Sons- UK
2004
4. Harfold Belofsky- Plastic design and processing hand book, Hanser publication-
2005
5. Beck- Plastic Product Design- van Nostrand Reignhold 2nd Edition
6. Asbhay, Selection of Materials, El Sevier Publications, 2006
Assessment:
PDE1011 COMPUTER AIDED PRODUCT DEVELOPMENT 04

1 Introduction to computer Graphics : Definitions, Classification, Architecture 10
of interactive computer Graphics, Applications Display & Interactive devices
Scan Conversion: Pixel plotting, scan conversion of Line, Circle, ellipse,
Parabola, Hyperbola. Effects of Scan conversion
Polygons: Types, Polygon filling using Boundary fill, edge fill ,Flood fill
algorithms, Scan conversion with Real Time scan conversion ,Run length
encoding, Cell encoding
2 Graphics Programming:- Graphics function, open GL interface, Co-ordinate 08
systems, Primitives & Attributes
Transformations:-2-D Transformations, 3-D Geometric & modeling
Transformations
3 2-D Viewing & Clipping, 3-D Viewing & Clipping , 3D viewing functions 08
Projection: General Projection Transformation, parallel & Perspective
Projections
4 Curves : Splines, Bezier & B-Spline Curves 06
Surfaces: Visible Surface detection methods, Hermite ,Bezier & B-Spilne
surfaces
5 Virtual Reality: Hidden Lines & Hidden Surfaces: Z-Buffer, Painters, Ray 08
Tracing, Area- Subdivision, Scan Line algorithm Light , Color & Shading
Models Animation.
6 CAD & Geometric Modeling: Features of Modeling &Assembly Packages, 08
Types of Geometric Modeling, geometry & topology, Data Structures, and
Product Data exchange Formats.
Fundamentals of CAE: General procedures of Numerical methods like FEM &
FDM, Kinematic analysis & Animation, Features and Application of
Commercial packages of CAE.
References:
1. Computer Grahics by F.S Hill. Jr
2. Computer graphics by Zhigang Xiang & Roy Plastock (Schaum’s outline’s)
3. Computer Graphics by Hearn & Baker
4. Mathematical elements for Computer Graphics by David F. Rogers, James Alan Adams
5. Procedural elements for Computer Graphics by David F. Rogers, James Alan Adams
6. Mastering CAD/CAM by Ibrahim Zeid
7. Geometric Modelling by Mortenson, M.E.
8. Interactive Computer Graphics by E.Angel & Dave Shreiner.
Assessment:
$
PDE1012 RELIABILITY ENGINEERING 04

1 Probability theory
Probability: Standard d e f i n i t i o n s a n d c o n c e p t s ; C o n d i t i o n a l
P r o b a b i l i t y , Bayer’s Theorem. Probability Distributions: Central tendency and
Dispersion; Binomial, Normal, Poisson, Weibull, Exponential, relations between them
09
and their significance. Measures o f D i s p e r s i o n : Mean M e d i a n , M o d e , R a n ge ,
M e a n D e v i a t i o n , Standard Deviation, Variance, Skewness, and Kurtosis.
2 Reliability Concepts
Reliability definitions, Importance of Reliability, Quality Assurance and
Reliability, Bath Tub Curve. Failure Data Analysis: Hazard rate, failure density,
Failure Rate, Mean Time To Failure (MTTF), MTBF, Reliability Functions.
Reliability Hazard Models: Constant Failure Rate, Linearly increasing, Time 10
Dependent Failure Rate, Weibull Model. Distribution functions and reliability
3 analysis.
System Reliability
System Configurations: Series, parallel, mixed configuration, k- out of n structure,
06
Complex systems.
4 Reliability Improvement
Redundancy Techniques: Element redundancy, Unit redundancy, Standby
redundancies. Markov analysis. System Reliability Analysis – Enumeration method,
07
Cut-set method, Success Path method, Decomposition method.
5 Maintainability and Availability
System downtime, Design for Maintainability : Maintenance requirements,
Design methods: Fault Isolation and self diagnostics, Parts standardization and
Interchangeability, Modularization and Accessibility, Repair Vs Replacement. 08
Availability – qualitative aspects.
6 Failure Mode, Effects and Criticality Analysis
Failure mode effects analysis, severity/criticality analysis, FMECA examples.
Fault tree construction, basic symbols, development of functional reliability 08
block diagram, Fau1t tree analysis and Event tree Analysis
$
Common for Machine Design and CAD/CAM, Robotics and PDD
References:
1. L.S. Srinath, “Reliability Engineering”, Affiliated East-West Press (P) Ltd., 1985.
2. Charles E. Ebeling, “Reliability and Maintainability Engineering”, Tata McGraw Hill.
3. B.S. Dhillion, C. Singh, “Engineering Reliability”, John Wiley & Sons, 1980.
4. P.D.T. Conor, “Practical Reliability Engineering”, John Wiley & Sons, 1985.
5. K.C. Kapur, L.R. Lamberson, “Reliability in Engineering Design”, John Wiley & Sons.
6. Murray R. Spiegel, “Probability and Statistics”, Tata McGraw-Hill Publishing Co. Ltd.
Assessment:
compulsory class test and the other is either a class test or
assignment on live problems or course project.
*
PDE1013 RAPID PROTOTYPING AND TOOLING 04

1 Rapid Prototyping 06
• Historical Development
• Applications: Design, Planning, Manufacturing and Tooling
• Applications: Automotive, Jewelry, Coin and Bio-Medical
• Fundamentals of Rapid Prototyping, Design Process
• Rapid Prototyping Process Chain
2 Subsystems of RP Machine 10
• Subsystems of RP machine
o Optical System
o Mechanical Scanning System
o Computer Interfacing hardware, DAQs
o Signal Flow, 3D Model to RP Prototype
• Introduction to 3D Modeling Softwares (Auto-CAD, PROE, CATIA,
IDEAs etc.)
• Slicing and Scan Path Generation Algorithms
• Data Conversion and Transmission
• File Formats, IGES, STL
• Preprocessing and Post-processing
3 Liquid Based Rapid Prototyping Systems 09

• Materials
• Stereolithography
• Solid Ground Curing
• Solid Object UV (Ultra-Violet) Printer
• Two Laser System
• Micro-stereolithography
4 Solid Based Rapid Prototyping Systems 09

• Materials
• LOM (Laminated Object Manufacturing) System
• FDM (Fuse Deposition Modeling) System
• Multi-Jet Modeling (MJM) System
• Model Maker and Pattern Master
• Shape Deposition Manufacturing Process
5 Powder Based Rapid Prototyping Systems 08
• Materials
• SLS (Selective Laser Sintering)
• (3DP) Three-Dimensional Printing
• (LENS) Laser Engineered Net Shaping
• (MJS) Multiphase Jet Solidification
• (EBM) Electron Beam Melting
6 Advances in RP Systems and Case Studies 06
• Advances in RP: Resolution & Accuracy issues, Integrated Hardening
Process, Two Photon Process for Micro/Nano Fabrication, Reverse
Engineering Process and Applications.
• Case Study: Wind-Tunnel Testing with RP Models
• Case Study: Investment Casting with RP
*
References:
1. Rapid prototyping, Andreas Gebhardt, Hanser Gardener Publications, 2003.

2. Rapid Prototyping and Engineering applications: A tool box for prototype development, Liou
W. Liou, Frank W. Liou, CRC Press, 2007.
3. Rapid Prototyping: Theory and practice, Ali K. Kamrani, Emad Abouel Nasr,
Assessment:
compulsory class test and the other is either a class test or
assignment on live problems or course project.
be set each of 20 marks, out of these any four questions to be
PDE1014 CREATIVITY IN DESIGN 04

1 INTRODUCTION: 05
Need for design creativity – creative thinking for quality – essential theory about
directed creativity
2 MECHANISM OF THINKING: 05
Definitions and theory of mechanisms of mind heuristics and models : attitudes,
Approaches and Actions that support creative thinking
3 VISUALIZATION: 10
Advanced study of visual elements and principles- line, plane, shape, form, pattern,
texture gradation, color
Symmetry. Spatial relationships and compositions in 2 and 3 dimensional space -
procedure for genuine graphical computer animation – Animation aerodynamics –
virtual environments in scientific Visualization – Unifying principle of data
management for scientific visualization - Visualization benchmarking
4 CREATIVITY: 10
Methods and tools for Directed Creativity – Basic Principles – Tools of Directed
Creativity – Tools that prepare the mind for creative thought – stimulation of new
ideas – Development and Actions: - Processes in creativity ICEDIP – Inspiration,
Clarification, Distillation, Perspiration, Evaluation and Incubation – Creativity and
Motivation The Bridge between man creativity and the rewards of innovativeness –
Applying Directed Creativity to the challenge of quality management
5 DESIGN: 09
Process Design, Emotional Design – Three levels of Design – Viceral, Behavioral and
Reflective- Recycling and availability-Creativity and customer needs analysis –
Innovative product and service designs, future directions in this application of
creativity thinking in quality management
6 INNOVATION: 09
Achieving Creativity – Introduction to TRIZ methodology of Inventive Problem
Solving - the essential factors – Innovator’s solution – creating and sustaining
successful growth – Disruptive Innovation model – Segmentive Models – New market
disruption - Commoditation and DE-commoditation – Managing the Strategy
Development Process – The Role of Senior Executive in Leading New Growth –
Passing the Baton
References:
1. Rousing Creativity: Think New NowFloyd Hurr, ISBN 1560525479, Crisp Publications Inc.
1999
2. Geoffrey Petty,” how to be better at Creativity”, The Industrial Society 1999
3. Donald A. Norman,” Emotional Design”, Perseus Books Group New York , 2004
4. Clayton M. Christensen Michael E. Raynor,” The Innovator’s Solution”, Harvard Business
School Press Boston, USA, 2003
5. Semyon D. Savransky,” Engineering of Creativity – TRIZ”, CRC Press New York USA,” 2000
Assessment:
Internal Assessment: Assessment consists of two tests out of which; one should be compulsory
class test and the other is either a class test or assignment on live problems
or course project.
End Semester Examination: Some guidelines for setting the question papers are as, six questions to be
set each of 20 marks, out of these any four questions to be attempted
by students. Minimum 80% syllabus should be covered in question papers
of end semester examination.
PDE1021 PRODUCT AND PROCESS ENGINEERING TOOLS 04

1 TOOLS FOR CONCEPT DEVELOPMENT 06
Products division, Quality function Deployment, concept engineering –Tools for
Design Development: design failure mode and design analysis, Reliability
prediction- Tools for Design Optimization: The Taguchi Loss Function, Optimizing
Reliability- Tools for Design Verification: Reliability Testing.
2 TOOLS FOR PROCESS IMPROVEMENT: 10
Process improvement methodologies, The Deming Cycle-FADE-Basic tools for
process improvement: flow charts, run charts and control charts, check sheets,
histograms, Pareto diagrams, Cause and Effect Diagrams-Scatter Diagrams-Other
tools for process improvement: Kaizen Blitz, Poka-yoke (mistake proofing),
process simulation-Engaging the work force in process improvement.
3 STATISTICAL PROCESS CONTROL: 08
Quality control measurements-SPC Methodology-Process capacity evaluation-
Control charts for variables data-Special Control charts for variables data- Process
Capability Evaluation- Control Charts for Attributes- Summary of control charts
construction chart, np-charts,c & u charts –Designing control charts: sampling ,
size, frequency-SPC.
4 Quality Management systems:- 06
ISO 9000:2000 AND SIX SIGMA-Pre control- Measurement systems Evaluation.
5 BENCHMARKING AND ESTABLISHING ENGINEERING 10
SPECIFICATIONS:
A Benchmarking Approach – Support tools for the benchmarking process: intended
assembly cost analysis, form diagram, trend analysis- Setting product
specifications: Basic & Advanced method.
6 PROJECT MANAGEMENT: 08
Understanding and representing tasks: Tasks, charts- Baseline project planning –
Accelerating projects-project execution- Postmortem execution
References:
1. Product Design Techniques in Reverse Engineering and New Product Development, KEVIN OTTO &
KRISTIN WOOD, Pearson Education (LPE), 2001.
2. The Management and control of Quality-6th edition-James R. Evens, William M Lindsay Pub: son
south-western
Assessment:
or course project.
set each of 20 marks, out of these any four questions to be attempted by
students. Minimum 80% syllabus should be covered in question papers of
end semester examination.
$
PDE1022 OPTIMIZATION 04

1 Basic Concepts: 08
Statement of the Optimization Problem, Basic Definitions, Optimality Criteria for
Unconstrained Optimization, Optimality Criteria for Constrained Optimization,
Engineering Application of Optimization, Overview of optimization technique,
Interdisciplinary nature, Introduction to related software.
2 Linear Programming Problem: 08
Formulation, Simplex method, Primal to Dual, Dual Simplex method, Sensitivity Analysis.
3 Integer L.P. Model: 08
Gomory’s cutting plane method, Branch & Bound Technique. Non L.P. Model: Lagrangian
method & Kuhn tucker method.
4 Unconstrained Optimization Technique: 08
Necessary and sufficient condition – search method (unrestricted Fibonacci and Golden)
– Interpolation method (Quadratic, Cubic & Direct root method). Direct search method –
Random search, Pattern search and Rosen Brock’s hill climbing method.
5 Newtonian Method: 08
Newton’s method, Marquardt’s method, Quasi Newton method. Discrete Event
Simulation: Generation of Random Variable, Simulation Processes, Monte-Carlo
Technique.
6 Response Surface Method: 08
Response Surface, The Least-Squares Methods, Two- Level Factorial Design, Addition of
Center Points, Central Composite Design(CCD), Sequential Nature of RSM, Other
Experimental Design
$
References:
1. RanjanGanguli, “Engineering Optimization - A Modern Approach” Universities Press
2. Pablo Pedregal, “Introduction to Optimization”, Springer
3. S.S. Rao, “Engineering Optimization - Theory and Practice”, John Wiley and Sons Inc.
4. L.C. Jhamb, “Quantitative Techniques Vol. 1 and 2”, Everest Pub. House
5. Pierre D.A., “Optimization, Theory with Application”, John Wiley & sons.
Assessment:
or course project.
PDE1023 PRODUCT PACKAGING 04

1 Introduction : 08
Definition
Functions of Packaging, package environment Product & Packaging, Material
Characteristics, Packaging Evaluation.
2 Packaging Media (Science, Technology, Manufacture, Conversion, 08
Properties & Applications):
Paper & Board, Fibre Board Boxes, Composite Containers, Drums, Celluloses,
Glass, Metal Containers and Components, Polymers and Plastics, Flexible
Packaging Materials, Wooden Containers, Crates, IBCs, Flexible & Rigid,
Textiles and Jute.
3 Quality Assessment & Performance Evaluation: 09
Testing, Significance of Testing, Quality Control and Quality Assurance, SQC
Techniques, Shelf- life Evaluation, Product Package Compatibility, Migration,
Transport-worthiness Testing, Testing of Ancillary Materials, Machine Material
Interaction, IMDG, UN / IATA Testing, etc.
4 Package Printing: 09
Pre-Press, Printing Processes, Letterpress, Offset, Lithography, Flexography,
Gravure, Screen, Pad, Foil Stamping, Digital Printing (Inkjet, Thermal),
Computer-to-Plate. Colour Management, Colour Measurement, etc.
Package Graphics:
Package Design, Role of Graphics, Package Aesthetics, Decoration Aspects,
Layout and Feature Selection, etc.
5 Package Storage and Handling: 07
Storage Types, Damage Control, Warehousing and Handling Equipments &
Techniques, etc.
6 Packaging & Environment: 07
Eco Issues, Wastage Control, Wastage Disposal, Eco Friendly Packaging, etc.
References:
1. Walter Soroka, “Fundamentals of packaging technology”, 3rd Edition, Institute of Packaging
professionals, Naperville, Illinois, USA, 2002.
2. Giles Calver, “What is Packaging Design? Essential design handbook”, Rotovision, 2004
3. Steven DuPuis, John Silva,”Package Design Workbook: The Art and Science of Successful
Packaging”, Rockport Publishers, 2008.
4. William H.Erdei, “Bar Codes – Design, Printing and Quality Control”, McGrawHill inc.,
1998.
5. Joseph F. Hanlon, Robert J. Kelsey, Hallie Forcinio, “Handbook of Packaging Engineering”,
3rd edition, CRC Press, 1998
6. Ronald E.Tood,” Printing Inks – Formulations, Principles, Manufacture, and Quality Control
Testing,” PIRA International1996
7. Davis, C.G., “Introduction to Packaging Machinery”, Packaging Machinery Manufacturers
Institute, 1997
8. M.Bakker, “Wlley Encyclopedia of Packaging Technology”, Joh Wiley & Sons Ltd., 2008
9. Sugan E. M.Solke, “Packaging and the Environment, Alternatives, Trends and Solutions”,
Technomic Publication, Revised Edition, 1994.
10. Nigel Thoobald, “Packaging closures & Sealing systems”, CRC Publishers, 2006erbert F.
Lund, “McGraw-Hill Recycling Handbook”, 2nd Edition, 2001.
Assessment:
compulsory class test and the other is either a class test or assignment
on live problems or course project.
be set each of 20 marks, out of these any four questions to be attempted
by students. Minimum 80% syllabus should be covered in question
papers of end semester examination.
PDE1024 DIE DESIGN AND DEVELOPMENT 04

1 Introduction to Manufacturing Process: 08
Shearing, Mechanics of Shearing, Shearing Forces, Blanking and Punching
Mechanisms, Bending, Mechanics of Deep Drawing, Various Forming Processes
such as Stretch Forming, Nosing, Expanding, Dimpling, Spinning, Flexible Die
Forming, Basic Die Classifications and Components
2 Tool and Die Materials: 08
Carbon and Alloy Steels, Designations for Carbon and Alloy Steels, Effects of
Various Alloy Elements in Steels, Carbon Steels, Alloy Steels, Machinability of
Steels, Mechanical Properties of Steels, Applications of Carbon and Alloy Steels,
Tool and Die Steels, Designation and Classification of Tool and Die Steels, Cold
Work Tool and Die Steels, Nonferrous Metals, Non-metallic Materials
3 Design of Blanking and Punching Dies: 08
Die Blocks, Die Opening Profile, Fastening to the Die Shoe, Sectioned Die,
Calculation of Die Block Dimensions, Punches, Punch Face, Geometry, Methods
for Assembling Punches, Punch Calculations, Stripper Plates, Stripper Force,
Stripper Design, Die Components for Guiding and Stopping, Stock Guides and
Guide Rails, Die Stops and French Notch Punch, Positioning the Individual Blank,
Pilots, Centre of Die Pressure, Examples of Couting Die Designs
4 Design of Bending Dies: 08
Simple Die Designs, U-Profile Bend Dies, V-profile Bend Dies, Universal Bending Dies,
Dies of Complex Design, Closing Profile Dies, Special Bending Dies, Curling and Hinge
Dies, Tube-forming Dies, Multiple-bend Dies, Combination Dies, Progressive Dies
5 Deep Drawing Dies: 08
Draw Rings, Draw Rings with Corner Radius, Draw Rings with Conical Profile,
Clearances and Tolerances, Calculation of the Dimensions of the Punch and Die,
Blank Holders, Blank Holder Pressure, Blank Holder Force, Draw Beads, Single-
operation Dies, Multi-operation Dies, Progressive Dies, Ironing Dies, Drawing Dies
for Pieces
6 Various Forming Dies: 08
Nosing Dies, Expanding and Bulging Dies, Expanding Dies, Bulging Dies, Flanging Dies
Die Process Quality And Automation, Die Maintenance:

Limit Switches, Sensors, Vision Control, Automation and In-Die Processes,
Automated Quality Control, Die Maintenance and Adjustments, Role of Software’s
in Die Design
References:
1. Ivana Suchy, “Handbook of Die Design” 2006, McGraw Hill, ISBN 0-07-146271-6
2. VukotaBoljanovic, “Sheet Metal Forming Processes and Die Design”, Industrial Press, New
York, ISBN 0-83 1 1-3 182-9
3. Joseph Vincent Woodworth, “Dies, Their Construction and Use for the Modern Working of
sheet Metals; A Treatise on the Design, Construction and Use of Dies, Punches”, 2010,
Cambridge Scholars Publishing, ISBN-13 9781152026681
4. David Smith, “Die Design Handbook” 3rd Edition, 1990, Society Of Manufacturing Engineers,
ISBN-13 9780872633759
5. VukotaBoljanovic , “Die Design Fundamentals” 3rd Edition, 2005, Industrial Press, ISBN-13
9780831131197
Assessment:
PDL101 CAD:SOLID MODELLING LAB 01
Create 3-D solid models of complex objects given a multi-view representation 08

I
(minimum 2 to 3)
Project: 16
For a given system consisting of four to five components do as described below;
1. Create solid models of individual parts
II 2. Create reference geometry features (planes, axes)
3. Create solid features using sweeping and lofting operations
4. Measure properties of 3-D CAD models
5. Create assemblies of CAD parts with appropriate mating relationships
Assessment:
Laboratory Project: Weightage for Laboratory Project should be 40% in Final Assessment
of Laboratory Work
End Semester Examination: Practical/Oral examination is to be conducted by pair of internal and
external examiners
PDL102 RAPID PROTOTYPING AND TOOLING LAB. 01

Following activity can be demonstrated either in the Institute or visiting any 08
organization where this type of work is done.
1. Study of reverse engineering concepts
2. Demonstration of 3D scanning
I 3. Study of rapid prototyping machines
4. Demonstration of Fusion Deposition Modelling
5. Demonstration of Selective Laser Sintering
6. Demonstration of Vacuum casting
7. Demonstration of Virtual Reality
Project: In a group of not more than 4 students 16
Identify an existing consumer product, develop CAD model, simulate in CAE
II
environment, optimize, develop tooling and make a physical prototype.
Prepare a detailed report.
Assessment:
Laboratory Project: Weightage for Laboratory Project should be 40% in Final Assessment
of Laboratory Work
external examiners
PDC201 PRODUCT LIFECYCLE MANAGEMENT 04

1 Introduction to Product Lifecycle Management (PLM): 08
Product Lifecycle Management (PLM), Need for PLM, Product Lifecycle Phases,
Opportunities of Globalization, Pre-PLM Environment, PLM Paradigm, Importance
& Benefits of PLM, Widespread Impact of PLM, Focus and Application, A PLM
Project, Starting the PLM Initiative, PLM
Applications
PLM Strategies:
Industrial strategies, Strategy elements, its identification, selection and
implementation, Developing PLM Vision and PLM Strategy , Change management
for PLM
2 Product and Product Data: 10
Product Importance, Range, Parts, Ingredients, Components, Assemblies, Identifier,
Requirements From Customer, Requirement to Product Specification, Identification
Standards, Unique Identifier, Unique Key, Traceability. Communication of
Identifier, Product Classification, Versions, Variants, Options, Product Ownership,
Product Structure and Architecture, Product Data types and importance, Product
Data Models
Product Data Management (PDM):
PDM systems and importance, Components of
PDM, Reason for implementing a PDM system, Financial justification of PDM,
Barriers to PDM implementation
3 Life Cycle Approach in Product Design: 10
Product–System Concept and Modelling, Product–System and Environmental
Impact, Environmental Aspects of the Consumption of Energy Resources, Emission
Phenomena and Environmental Effects, Life Cycle Modelling, Modelling by
Elementary Function or Activity, Typologies of Activity Models, Product Life
Cycle: Reference Model, Main Phases of the Life Cycle, Preproduction, Production,
Distribution, Use , Retirement and Disposal, Flows of Material Resources and
Recovery Levels, Life Cycle Approach in Product Design
4 Life Cycle Assessment and Life Cycle Cost Analysis: 08

Properties, and Framework of Life Cycle Assessment, Phases of LCA in ISO
Standards, Fields of Application and Limitations of Life Cycle Assessment, Cost
Analysis and the Life Cycle Approach, General Framework for LCCA, Evolution of
Models for Product Life Cycle Cost Analysis
5 Integration of Environmental Aspects in Product Design: 06
Sustainable Development, Design for Environment, Need for Life Cycle
Environmental Strategies, Useful Life Extension Strategies, End-of-Life Strategies,
Introduction of Environmental Strategies into the Design Process, Life Cycle
Environmental Strategies and Considerations for Product Design
6 Integration of the PLM system with other applications: 06
Transfer file, Database integration, System roles ERP, CAD, Configurators, EAI,
PLM and Service Industry, PLM and E- Business
PLM Case Studies: PLM Softwares, Tools, PLM Success: Case Studies, Examples
References:
1. John Stark, “Product Lifecycle Management: Paradigm for 21st Century Product Realisation”,
Springer-Verlag, 2004. ISBN: 1852338105
2. Fabio Giudice, Guido La Rosa, AntoninoRisitano, “Product Design for the environment-A life
cycle approach”, Taylor & Francis 2006, ISBN: 0849327229
3. SaaksvuoriAntti, ImmonenAnselmie, “Product Life Cycle Management”, Springer, Dreamtech,
ISBN: 3540257314
4. Michael Grieve, “Product Lifecycle Management: Driving the next generation of lean
thinking”, Tata McGraw Hill, 2006, ISBN: 0070636265
Assessment:
PDC202 DESIGN FOR X 04

1 DESIGN FOR MANUFACTURE :
General design principles for manufacturability - strength and mechanical factors,
mechanisms selection, evaluation method, Process capability - Feature tolerances - 08
Geometric tolerances - Assembly limits – Datum features - Tolerance stacks
2 DESIGN FOR ASSEMBLY:
Assembly processes-Handling and insertion process-Manual, automatic and robotic 08
assembly-Cost of Assembly-Number of Parts-DFA guidelines
3 VALUE ENGINEERING:
Value –types –functional –operational –aesthetic –cost- –material – Design process –
value and worthiness –procedure -brainstorming sessions –evaluation –case studies – 08
value estimation- Value analysis - Design for value - Selection of alternatives -
optimization – Implementation
4 PRODUCT DEVELOPMENT ECONOMICS:
Elements of Economics analysis-Quantitative and qualitative analysis-Economic
Analysis process-Estimating magnitude and time of future cash inflows and out flows- 10
Sensitivity analysis-Project trade-offs-Trade-offs rules-Limitation of quantitative
analysis- Influence of qualitative factors on project success
5 CONCEPT OF RELIABILITY:
Introduction: The study of Reliability and Maintainability, Concepts, Terms and
Definitions, Applications, The Failure Distribution: The reliability Function, Mean 08
Time to Failure, Hazard Rate Function, Bath tub Curve, Conditional Reliability
6 MAINTAINABILITY:
Analysis of down time, Report Time Distribution, Stochastic Point Processes,
06
Reliability under Preventive Maintenance, State-Dependant System with Repair,
Design for Maintainability.
References:
1. Harry Peck, Designing for Manufacture, Pitman Publications, 1983.
2. George E Dieter, Engineering Design, McGraw-Hill Int Editions, 2000
3. S.S.Iyer, Value Engineering, New Age International, 2000
4. Charles E. Ebeling, An Introduction to Reliability and Maintainability Engineering, TMH 2000
Assessment:
or course project.
Course Course Name Credits
Code
PDC203 APPLIED ERGONOMICS 04

1 Human Factors Basics:
Introduction to Human Factors, Research Methods, Design and Evaluation Tools, Visual 08
Sensory System, Auditory, Tactile, and Vestibular Systems.
2 Human-Machine System:
06
Cognition, Decision Making, Displays, Control
3 Human Performance in the Workplace:
Anthropometry and Workplace Design, Biomechanics of Work, Work Physiology, 08
Stress and Workload
4 Ergonomics - Physical design :
User-technology physical interface design
Who are the users? How does the technology fit different user dimensions? How does
the technology fit user anatomy? How does the technology fit user strength? How does 10
the technology accommodate different abilities? How safe is the technology (health,
comfort, performance)? How do users interact with technology?
5 Introduction to the concept of system design and Ergonomics

Ergonomics in product design, the interface design, Body dimensions and its application
in design, Dimensional optimization for the population and use of percentile, The
musculo-skeletal system and joint motion study, Human body following the principle of
lever, biomechanical stresses on our body. Effect of stresses imposed on body. Design 10
from the view point of biomechanics, Work posture analysis, Static and Dynamic work,
the visual, auditory and thermal environment and their impact on design. Controls and
display aspects of design. Research techniques in Ergonomic data generation,
interpretation and application of statistical methods.
6 Introduction to basic elements of design and Ergonomics :

Line, texture, colour, form, symmetry, balance, scale, mass, unity and variety. Concept
of visual language and visual design. Introduction to Gestalt laws, composition and 06
figure and ground relationships. Introduction to concept of negative space, Use of
symmetry. Generation of patterns and textures using simple elements.
References:
1. M. S. Sanders and Ernest J. McCormick: Human Factors in engineering and Design, Sixth
Edi.,McGraw-Hill International Editions, 1987.
2. P.O. Astrand and K. Rodahl, Textbook of work physiology, McGraw Hill, New York, 1970.
3. Wickens, C.D., Lee, J.D., Liu, Y., Gordon Becker, S.E. (2004). An Introduction to Human
Factors in Engineering (2nd Ed.). Upper Saddle River, New Jersey: Pearson Prentice-Hall
Assessment:
or course project.
PDE2031 VEHICLE DESIGN 04

1. Automotive engineering development: 08
Innovation and Inventions, Styling Development, Streamlining, Engine Developments,
Transmission Developments, Steering, Brakes, Suspension, Wheels and Tyres, Interior
Refinement, Safety Design
2. Modern materials and their incorporation into vehicle design: 08
Structure and manufacturing technology of automotive materials, Metals and Alloys,
Plastics and Polymers, Ceramics and Glasses, Composite Materials, Mechanical and
Physical Properties of Automotive Materials, Selection of Automotive Materials
3. Body design: The styling process: 08
The Studios, working environment and structure, Product Planning, Concept sketching
and Package related sketching, Full sized tape drawing, Clay Modelling, Use of 2D
CAD system, Use of 3D CAD System, Rendering Techniques
4. Body design: Aerodynamics: 08
Aerodynamic forces, Drag, Drag reduction, Stability and cross winds, Noise,
Ventilation, Wind tunnel testing, Use of CFD
Basic Concepts in Design and Analysis:
Chassis, Suspension systems, Braking systems, Transmission and driveline, Noise and
Vibration
5. Occupant accommodation: an ergonomics approach: 08
Ergonomics in Automotive Industry, Ergonomic methods and tools to promote occupant
accommodation, Standards, Guidelines and Recommendations, Anthropometry, Testing
6. Future trends in automobile design: 08
Mechanical possibilities, Advances in Manufacturing Methods, Materials advances,
Energy conservation, Power systems, Electrical, Electronic and Hybrid possibilities,
Vehicle information and navigation systems
References:
1. Julian Happian-Smith , “An Introduction to Modern Vehicle Design”, 2002, Butterworth-
Heinemann, ISBN 07506 5044 3
2. John Fenton, “Advances in Vehicle Design”, 1999, Professional Engineering Publishing,
ISBN-13 9781860581816
3. Sanders, M.S. and McCormick, E.J., “Human Factors in Engineering and Design” (7th edition)
McGraw-Hill
4. Smith, W.F. (1993). “Fundamentals of Materials Science and Engineering.” McGraw-Hill
,ISBN 0-07-059202-0
5. Beranek, L.L. (1971). “Noise and Vibration Control”. McGraw-Hill.
6. Bralla, J.B. (ed.) (1986). “Handbook of Product Design for Manufacturing – a Practical Guide
to Low Cost Production.” McGraw-Hill. ISBN 0-07-007130-6.
7. Ryan Boroff, Tony Lewin, “How to Design Cars Like a Pro”,2010, Motorbooks International,
ISBN-13 9780760336953
8. Geoff Wardle, Freeman Thomas, Stacey Macey, Ralph Gilles, Gordon Murray, Stuart Macey,
“H-point: The Fundamentals of Car Design and Packaging”,2009, Ingram Pub Services, ISBN-
13 9781933492377
9. MR Fernando F. Palma P., “Car Design: Futuristic Concepts”,2009, Createspace, ISBN-13
9781448618767
10. Bilal Salim, “Design and Fabrication of a Hybrid Car”,2012, LAP Lambert Academic
Publishing, ISBN-13 9783659157264
Assessment:
PDE2032 POLYMERIC MATERIAL AND PROCESSING 4

1 Introduction 6
The terminology of plastics
The early history of polymers
The development of plastic products
Designing a polymer structure for improved properties
2 Plastic properties: 8
Mechanical Properties, Reinforced Properties, Electrical properties, Optical
properties, Thermal Properties, Testing of Plastics
3 Fabrication process: 10
Types of process, tooling for plastic processing, compression moulding, Transfer
moulding, Injection moulding of thermoplastics, Injection moulding of
thermosetting resins, Extrusion, Blow Moulding, Calendaring. Casting process,
Foaming Process, Reinforcing process,
4 Industrial Polymers: 8
4.1 Addition Polymers: Polyolefins, Olefins copolymers, Acrylic, Vinayl
polymers.
4.2 Condensation polymers: Polyesters, polyamides, formaldehydes resins
Polyurethanes, Eather polymers, cellulosic Polymer, Silicones, Polyblends
Interpenetrating polymer Network.
5 Polymers in special uses : 8
High temperature and fire resistance, liquid crystal Polymers, electro active
polymer, Polymer supported catalystes optical Information storage.
6 Plastics and the environment 8
how plastics affect the environment, how environmental factors affect plastics
behavior of plastics in outdoors environments, behavior of plastics in biotic
environments, behavior of plastics in fires environment.
References:
1. Industrial Polymers, Specialty Polymers, and Their Applications Manas Chanda and Salil K .
Roy CRC Press 2008 Print ISBN: 978-1-4200-8058-2 eBook ISBN: 978-1-4200-8059-9
2. Plastics and the Environment Anthony L. Andrady ISBN: 978-0-471-09520-0
3. Design of Plastic Products Charles A. Harper: Modern Plastics Handbook. (McGraw-Hill
Professional, 2000),
4. Life Cycle Engineering of Plastics: Technology, Economy and Environment Edited By L.
Lundquist Y. Leterrier P. Sunderland Imprint: Elsevier ISBN: 978-0-08-043886-3
5. Plastic product design Ronald D. Beck Van Nostrand Reinhold Co., 1980 - Technology &
Engineering -3 .Plastics Technology Handbook, Third Edition, edited by Manas Chanda, Salil
K. Roy
6. Plastics and the Environment Anthony L. Andrady John Wiley & Sons
Assessment:
or course project.
Course Course Name Credits
Code
PDE2033 ROBOTICS* 04

1 Introduction: Automation & robotics, Robotic System & Anatomy Classification, 08
Future Prospects
Robotic Application in Manufacturing: Material transfer, Machine loading &
unloading, Processing operations, Assembly & Inspectors
Social Issues and Economics of robotics Drives: Control Loops, Basic Control
System Concepts & Models, Control System Analysis, Robot Activation & Feedback
Components, Position & Velocity Sensors, Actuators, Power Transmission Systems.
2 Robot &its Peripherals: End Effecters - types, Mechanical & other grippers, Tool as 08
end effecter
Sensors: Sensors in Robotics, Tactile Sensors, Proximity & Range Sensors, Sensor
Based Systems
3 Robotic Cell Design Coordinate
& Control.Frames, Rotations, Homogeneous Coordinates, Arm 08
Robot Kinematics:
Equation of Planer Robot, Four axes SCARA Robot, TCV, Inverse Kinematics of
Planer Robot, and Four Axis SCARA Robot.
4 Trajectory Planning & Robot Dynamics: Manipulator Path Control- Linear, 08
Quadratic and Cubic Interpolation, Work Space Analysis, Robot Dynamics –
Langrangian Dynamics of one and two link robot arm
5 Machine Vision: Introduction, Low level & High level vision, Sensing &Digitising, 08
Image processing & analysis, Segmentation, Edge detection, Object description&
recognition, Interpretation, Noises in Image, Applications
6 Programming For Robots: Methods, Robot programme as a path in space, Motion 08
interpolation, level & task level languages, Robot languages; Programming in suitable
languages Characteristics of robot
Robot Intellgence& Task Planning: Introduction, State space search, Problem
reduction, Use of predictive logic, Means -Ends Analysis, Problem solving, Robot
learning, Robot task planning.
* Common for Machine Design, Automobile Engineering, CAD/CAM and Robotics and PDD
References:
1. YoremKoren, “Robotics for Engineers”
2. J. F. Engelberger, “Robotics in Practice”
3. Ulrich Rembolds, ChristialBlume, “Computer Integrated Manufacturing Technology and
Systems”
4. Ramamurthy, “Computer Aided Design in Mechanical Engineering”
5. Mark Spong, “Robot Dynamics and Control”, Wiley India
6. John Craig, “Robotics”
7. Paul R.P., “Robot Manipulators: Mathematics, Programming and Control”
8. Groover and Simmers, “Industrial Robotics”
9. Ernest Deoblin, “Measurement systems”
10. Beckwith and Lewisbuck, “Mechanical Measurements”
11. K. Ogata, “Modern Control Engineering”,PHI
12. Benjamin Kuo, “Automatic Control Systems”, Wiley India
13. Richard D. KIafter et al, “Robotic Engineering -an Integrated Approach”, PHI
14. Spyros G. Tzafestas, “Intelligent Robotic Systems”
Assessment:
or course project.
PDE2034 MICRO ELECTRO MECHANICAL SYSTEMS@ 04

1 Introduction to MEMS & Applications 06
• Introduction to Micro-Electro-Mechanical Systems,
• Applications and Materials,
• Advantages & Disadvantages of Micro-sensors, and micro-actuators.
2 Sensors and Actuators in Micro-domain 10
• Concept of Sensors & Actuators,
• Sensing & Actuation Principles: Mechanical Sensing, Capacitive, Electrostatic,
Electromagnetic, Piezo Resistive, Piezo Electric, Thin Films, Shape Memory
Alloys
• Comb Drive Actuation & Sensing. Micro-mechanisms, Air-Bag Sensors,
Chemical Sensors
• Sensors & Actuators for Automotive, Biomedical, Industrial applications
• Design of sensor and actuator for few applications such as automobile
Accelerometer, bimetallic temperature sensor, etc.
3 Fabrication Methods 08
Microfabrication Methods (VLSI Techniques)
• Positive and Negative Photoresists,
• Bulk Micromachining,
• Surface Micromachining,
• Etching (Isotropic and Anisotropic),
• Deposition techniques such as CVD (Chemical Vapor Deposition),
Metallization Techniques.
3D High Aspect Ratio Techniques
• LIGA,
• AMANDA,
• Microstereolithography,
• IH-Process,
• X-Ray Techniques,
• Ion-beam Lithography etc.
4 Modelling and Simulation Techniques 08
• Scaling Laws, Governing Equations
• Modelling of Mechanical Structures via classical methods, Newtons
Laws, Thermal Laws, Fluid Flow Analysis
• Micro-mechanism modelling and analysis techniques : Lumped Parameter
Modelling and Distributed Parameter Modeling
• Modelling of Micro-channel as heat exchanger, accelerometers, microhinges,
compound microstructures.
• Linear & Nonlinear Model.
• Numerical Methods used for MEMS analysis.
5 Characterization Techniques 10
Topography Methods (Optical, Electrical and Mechanical Methods)
• Microscopy, STM (Scanning Tunneling Microscopes),
• SEM (Scanning Electron Microscopes),SPM (Scanning Probe
Microscopes), AFM (Atomic Force Microscopes)
Mechanical Structure Analysis
• Deformation & Vibration Measurement Techniques (Piezo resistive and
piezo electric)
• Interferometry Techniques,
• SPI (Speckle Pattern Interferometry), ESPI (Electronic Speckle Pattern
Interferometry),
• Laser Techniques, Laser Doppler Vibro-meters
Fluid, Thermal and Chemical Analysis
• Thermal Analysis Techniques (Theoretical and Experimental),
• Fluid Flow Pattern Analysis,
• Electro-chemical Analysis,
• PIV Techniques
• Spectroscopy
6 Introduction to Advances of MEMS and Nanotechnology 06
• CNT (Carbon Nano Tubes) Applications, its properties, and Fabrication
Method,
• Nano-mechanical Systems (NEMS),
• Nano-tribology, &nano-indentation techniques,
• Domestic and Industrial Applications of nanotechnology
• Molecular Modelling Techniques.
• Social and Ethical Implications of nanotechnology in Society
@
Common for Machine Design, Automobile Engineering, CAD/CAM and Robotics, Manufacturing
Systems Engineering and PDD
References:
1. Julian W. Garden, Vijay K. Varadan and Osama O. Awadelkarim “Microsensors MEMS and
Smart devices”, John Wiley and sons, Ltd.
2. NadimMulaf and Kirt Williams, “An Introduction to Microelectromechanical systems
Engineering”, Artech House.
3. NicolaeLobontiu and Ephrahim Garcia, “Mechanics of Microelectromechanical systems”,
Kluwer Academic Publication.
4. Stanley Wolf and Richard Tauber, “Silicon Processing for the VLSI era Volume -1 Technology”,
Lattice press.
5. Vijay K. Varadan, K.J.Vinoy and S. Gopalkrishnan, “Smart Material Systems and MEMS:
Design and Development Methodologies”, John Wiley and sons Ltd.
6. Bhushan, “Springer Handbook of Nanotechnology”, Springer Inc.
Assessment:
or course project.
PDE2041 REVERSE ENGINEERING 04

1 Introduction 08
Historical Background, Industrial Evolution, Reinvention of Engineering Marvels
from Nature, Reverse Engineering in Modern Industries, Reverse Engineering vs.
Machine Design, Motivation and Challenge, Analysis and Verification,
Accreditation, Part Criticality, Applications of Reverse Engineering
2 Geometrical Form 08
Surface and Solid Model Reconstruction, Scanning Instruments and Technology,
Principles of Imaging, Cross-Sectional Scanning, Digital Data, Computational
Graphics and Modeling, Data Refinement and Exchangeability, Dimensional
Measurement, Case Studies, Part Tolerance, Prototyping, Additive Prototyping
Technologies, Subtractive Prototyping Processes, Rapid Injection Molding, Steps of
Geometric Modeling
3 Material Characteristics and Analysis 08
Alloy Structure Equivalency, Phase Formation and Identification, Mechanical
Strength, Hardness
Part Durability and Life Limitation
Part Failure Analysis, Fatigue, Creep and Stress Rupture, Environmentally Induced
Failure
4 Material Identification and Process Verification 08
Material Specification, Composition Determination, Microstructure Analysis,
Manufacturing Process Verification
5 Data Process and Analysis 08
Statistical Analysis, Data Analysis, Reliability and the Theory of Interference,
Weibull Analysis, Data Conformity and Acceptance, Data Report
Part Performance and System Compatibility
Performance Criteria, Methodology of Performance Evaluation, System
Compatibility
6 Acceptance and Legality 08
Legality of Reverse Engineering, Legal Definition of Reverse Engineering, Legal
Precedents on Reverse Engineering, Patent, Copyrights, Copyright Codes, Legal
Precedents on Copyrights, Trade Secret, Case Study of Reverse Engineering a Trade
Secret, Third-Party Materials
References:
1. Wego Wang, “Reverse Engineering: Technology of Reinvention”, ISBN-13: 978-1439806302,
CRC Press
2. Kevin Otto , “Product Design : Techniques in Reverse Engineering and New Product
Development”, ISBN-13: 9788177588217, Dorling Kindersley
3. Robert Messler, “Reverse Engineering: Mechanisms, Structures, Systems & Materials”,
McGraw Hill Education, ISBN: 9780071825160
4. Raja, Vinesh, Fernandes, Kiran J. , “Reverse Engineering An Industrial Perspective” ISBN
978-1-84628-856-2, Springer
Assessment:
PDE2042 PRODUCT MARKETING 04

Advanced Marketing Planning 08
Introduction: Concept, nature, scope and importance of marketing; Marketing
1 concept and its evolution; Marketing mix; Strategic marketing planning – an
overview.
Market Analysis and Selection: Marketing environment – macro and micro
components and their impact on marketing decisions; Market segmentation and
positioning;
Consumer Behaviour 08
Introduction to Consumer Behaviour (CB): Nature and Importance of CB,
2 application of CB in Marketing , Consumer Research process.
Consumer Decision making Process:
· Problem recognition
· Information Search Process and Evaluation
· Purchasing process
· Post purchase behaviour
Marketing Research 10
An overview of the Marketing Research Process, Research Designs, Exploratory
3 Research, Descriptive Research, Experimental Research,
Uncontrollable Variables:
History, Maturation, Testing Effect, Measurement of Variation and Interactive
Effect. Types of Data-Primary Data and Secondary Data, Secondary Data Sources
for MR in India.
Pricing Strategies 08
An Introduction to Pricing Basic Frameworks
4 Overview of common pricing methods
Psychology and Measurement
The role of consumer psychology in pricing
Price Discrimination
Effective market segmentation
New product pricing and building
Brand Strategy 08
Concept of Brand, Significance of Branding for Consumers and for Firms,
5 Branding Challenges and Opportunities, Concept of Brand Equity, Cost based,
Price based and Customer based Brand
Equity, Customer Based Brand Equity
Sources of Brand Equity- Brand Awareness and Brand Image, Keller’s CBBE
Model- Identity,
Meaning, Response and Relationships.
Brand Positioning
Definition of Target Market & Market Segmentation, Defining the Competitive
Frame of Reference, Establishing the Points of Parity & Points of difference.
Designing the Supply Chain network 06
Understanding the supply Chain, Designing the distribution network, Designing
6 and Planning Transportation Network
References:
1. Kotlar, Philip, Marketing Management, Prentice Hall, New Delhi.
2. Loudan, David L and Bitta, A.J. Della Consumer Behaviour
3. Schiffman LG and Kanuk LL Consumer Behaviour
4. Nair, Suja R, Consumer Behaviour in Indian
5. Marketing Research: Text & Cases, Boyd, Westfall & Stasch, R D Irwin
6. Research For Marketing Decisions, Green & Tull, Prentice Hall
7. Thomas T. Nagle, the Strategy and Tactics of Pricing, Prentice Hall
8. Pricing a Portfolio of Products complements & substitutes new product pricing
9. Strategic Brand Management, Keller, Parmeswaran & Jacob, Pearson
10. Brand Management, Kirti Dutta, Oxford Publishing
11. Supply Chain Management Strategy, Planning and Operationby Sunil Chopra, Pearson
Education
Assessment:
or course project.
PDE2043 COMPOSITE MATERIAL$ 04

1 Introduction to Composite Materials 08
 Basic Concepts and Terminology
 Classification -Polymer Matrix Composites, Metal Matrix Composites, Ceramic
Matrix Composites, Carbon–Carbon Composites
 Current and Potential Advantages and Applications of Composite Materials
2 Macromechanical Behaviour of a Lamina 08

 Review of Definitions:
- Stress, Strain, Elastic Moduli, Strain Energy
 Hooke’s Law for Different Types of Materials
- Anisotropic Material, Monoclinic Material, Orthotropic Material
(Orthogonally Anisotropic)/SpeciallyOrthotropic, Transversely Isotropic
Material, Isotropic Material
 Hooke’s Law for a Two-Dimensional Unidirectional Lamina
- Plane Stress Assumption, Reduction of Hooke’s Law in Three Dimensions
to TwoDimensions, Relationship of Compliance and Stiffness Matrix
toEngineering Elastic Constants of a Lamina
 Hooke’s Law for a Two-Dimensional AngleLamina
 Engineering Constants of an Angle Lamina
 Invariant Form of Stiffness and Compliance Matrices for anAngle Lamina
 Strength Failure Theories of an Angle Lamina
- Maximum Stress Failure Theory, Strength Ratio, Failure Envelopes,
Maximum Strain Failure Theory, Tsai–Hill Failure Theory, Tsai–Wu
Failure Theory
3 Micromechanical Behaviour of a Lamina 08
 Volume and Mass Fractions, Density, and Void Content
- Volume Fractions, Mass Fractions, Density, Void Content
 Evaluation of the Four Elastic Moduli by Strength of Materials Approach,
Semi-Empirical Models and Elasticity Approach
 Elastic Moduli of Lamina with Transversely Isotropic Fibers
 Ultimate Strengths of a Unidirectional Lamina
- Longitudinal Tensile Strength, Longitudinal Compressive, Transverse
Tensile Strength, Transverse Compressive Strength, In-Plane Shear Strength
4 MacromechanicalBehaviour of a Laminate 08
 Introduction
 Laminate Code
 Classical Laminated Plate Theory
 First Order Laminated Plate Theory
 Laminated Stiffnesses for Selected Laminates
- Single Layered Configurations, Symmetric Laminates, Antisymmetric
Laminates, Balanced and Quasi-Isotropic Laminates
5 Failure, Analysis and Design of Laminates 08
 Introduction
 Failure Criterion for a Laminate
 Design of a Laminated Composite
 Other Mechanical Design Issues
- Sandwich Composites, Long-Term Environmental Effects, Interlaminar
Stresses, Impact Resistance, Fracture Resistance, Fatigue Resistance
6 Introduction to Fabrication Techniques for Composites 08
 Polymer Composites
- Liquid Resin Impregnation Routes, Pressurized Consolidation of Resin Pre-
Pregs, Consolidation of Resin Moulding Compounds, Injection Moulding of
Thermoplastics, Hot Press Moulding of Thermoplastics
 Metal Composites
- Squeeze Infiltration, Stir Casting, Spray Deposition, Powder Blending and
Consolidation, Diffusion Bonding of Foils, Physical Vapour Deposition
(PVD)
 Ceramic Composites
- Powder-Based Routes, Reactive Processing, Layered Ceramic Composites,
Carbon/Carbon Composites
$
References:
1. R.M. Jones, “Mechanics of Composite Materials”, Taylor and Francis, Inc.
2. J.N. Reddy, “Mechanics of Laminated Composite Plates and Shells – Theory and Analysis”, CRC
Press
3. A.K. Kaw, “Mechanics of Composite Materials”, Taylor and Francis Group, LLC
4. D. Hull and T.W. Clyne, “An Introduction to Composite Materials”, Cambridge University Press
5. L.P. Kollar, G.S. Springer, “Mechanics of Composite Structures”, Cambridge University Press
Assessment:
or course project.
*
PDE2044 SMART MATERIALS AND APPLICATIONS 04

1 Introduction to Smart / Intelligent Materials: 06
Overview of Smart / Intelligent Materials, Primitive Functions of Intelligent Materials,
Intelligence Inherent in Materials, Actuator Materials, Sensing Technologies, Micro
sensors, Intelligent Systems, Hybrid Smart Materials, Passive Sensory Smart
Structures, Reactive Actuator based Smart Structures, Active Sensing and Reactive
Smart Structures, Smart Skins
2 Introduction to High bandwidth - Low strain generating (HBLS) 08
Smart Materials
Piezoelectric Materials
constitutive relationship, electromechanicalcoupling coefficients, piezoelectric constants,
piezoceramic materials, variation of coupling coefficients in hard and soft piezoceramics,
polycrystalline vs. single crystal piezoelectric materials, polyvinyldenefluoride,
piezoelectric composites
Magnetostrictive Materials
constitutive relationship, magnetomechanical couplingcoefficients, Joule Effect, Villari
Effect, MatteuciEffect, Wiedemanneffect, Giantmagnetostriction, InTerfenol-D,
Terfenol-Dparticulate composites, Galfenol and Metglasmaterials.
3 Actuators based on HBLS Smart Materials 10
Piezoelectric Actuators
Induced Strain actuation model, Unimorph and Bimorph Actuators, Actuators embedded
in composite laminate, Impedance matching in actuator design, Feedback Control, Pulse
Drive, Resonance Drive.
Magnetostrictive Actuators
Magnetostrictive MiniActuators, Thermal instabilities, Discretely distributed
actuation,ManetostrictiveComposites.
MEMS based Actuators
Piezoelectric Micropumps, Magnetostrictive micromechanisms, Imaging System
Applications, Inchworm Devices, Inkjet Printers, Piezoelectric Relays, Ultrasonic
Motors, and Micro scale Walking Machines.
Sensors based on HBLS Smart Materials
Piezoelectric Sensors, Magnetostrictive Sensors, Techniques of Self- Sensing, MEMS
Sensors
4 Introduction to Low bandwidth - High strain generating (LBHS) materials Shape 07
Memory Alloys(SMA) Electro-active Polymers (EAP)
5 Actuators based on LBHS Smart Materials 09
Shape Memory Alloy based actuators for Shape Control Electro- active Polymers for
Work-Volume Generation Sensors based on LBHS Smart Materials EAP based sensors
SMA based encoders, Optical Fibre based Sensing
6 Advances in Smart Materials 08
• Active Fibre Composites (AFC)
• Energy Harvesting Actuators and Energy Scavenging Sensors
• Self-healing and Autophagous Smart Materials
*
Common for Machine Design, Automobile Engineering, CAD/CAM and Robotics and PDD
References:
1. M.V. Gandhi and B.S. Thompson, “Smart Materials and Structures”, Chapman &
Hall,London; New York, 1992 (ISBN: 0412370107)
2. Bryan Culshaw, “Smart Structures and Materials”, Artech House
3. Mel Scwartz, “Encyclopedia of Smart Materials Vol. I and II”, John Wiley & Sons
4. SenolUtku, “Theory of Adaptive Structures : Incorporating Intelligence into Engineered
Products”, CRC Press
5. H. Janocha, “Actuators - Basics and Applications”,Springer
6. B. Culshaw, “Smart Structures and Materials”, Artech House, Boston, 1996 (ISBN:
0890066817)
7. A.V. Srinivasan, “Smart Structures: Analysis and Design”, Cambridge University
Press,Cambridge; New York, 2001 (ISBN: 0521650267)
8. A.J. Moulson and J.M. Herbert, “Electroceramics: Materials, Properties, Applications”,2nd
Edition, John Wiley & Sons, Chichester, West Sussex; New York, 2003 (ISBN:0471497479)
9. G. Gautschi, “Piezoelectric Sensorics: Force, Strain, Pressure, Acceleration and Acoustic
Emission Sensors, Materials and Amplifiers”, Springer, Berlin; New York, 2002
(ISBN:3540422595)
10. K. Uchino, “Piezoelectric Actuators and Ultrasonic Motors”, Kluwer Academic Publishers, Boston,
1997 (ISBN: 0792398114)
11. G. Engdahl, “Handbook of Giant Magnetostrictive Materials”, Academic Press, San Diego, Calif.;
London, 2000 (ISBN: 012238640X)
12. K. Otsuka and C.M. Wayman, “Shape Memory Materials”, Cambridge University Press,
Cambridge; New York, 1998 (ISBN: 052144487X)
13. Eric Udd, “Fibre Optic Sensors: An Introduction for Engineers and Scientists”, John Wiley & Sons,
New York, 1991 (ISBN: 0471830070)
14. André Preumont, “Vibration Control of Active Structures: An Introduction”, 2nd Edition, Kluwer
Academic Publishers, Dordrecht; Boston, 2002 (ISBN: 1402004966)
15. HojjatAdeli, “Control, Optimization, and Smart Structures: High-Performance Bridges and
Buildings of the Future”, John Wiley, New York, 1999 (ISBN: 047135094X)
16. T.T. Soong, “Passive Energy Dissipation Systems in Structural Engineering”, Wiley,
Chichester; New York, 1997 (ISBN: 0471968218)
Assessment:
in question papers of end semester
PDL203 CAD: SURFACE MODELLING LAB 01

Introduction to surface modelling 10
1. Coordinate transformations (translation, rotation, scaling, reflection)
2. Working with drawings, views, dimensions and tolerances.
I
3. Sheet metal design
4. Surface Modelling
II Project: 14
Create CAD models of any two given objects involving above features, such as car
side mirror body, mouse body, bottles etc.
Assessment:
Laboratory Project: Weightage for Laboratory Project should be 40% in Final Assessment of
Laboratory Work
external examiners
PDL204 COMPUTER AIDED ENGINEERING LAB. 01

Introduction to computer aided engineering 14
1. Modelling of an element/system
2. Finite Element Analysis of an element/system (Involves element
I selection, assigning properties, meshing, assigning loads and boundary
conditions, analysis and result interpretation)
3. Optimization of an element/system (minimization of mass) through
FEA.
Project: 10
II Select any engineering element/system and optimize the design through FEA
approach
Assessment:
Laboratory Project: Weightage for Laboratory Project should be 40% in Final Assessment of
Laboratory Work
external examiners
PDS301 Seminar 03
Guidelines for Seminar
o Seminar should be based on thrust areas in Mechanical Engineering
o Students should do literature survey and identify the topic of seminar and finalize in
consultation with Guide/Supervisor. Students should use multiple literature and understand
the topic and compile the report in standard format and present in front of Panel of
Examiners appointed by the Head of the Department/Institute of respective Programme.
o Seminar should be assessed based on following points
 Quality of Literature survey and Novelty in the topic
 Relevance to the specialization
 Understanding of the topic
 Quality of Written and Oral Presentation
PDD 301 / Dissertation (I and II) 12 +
PDD 401 15
Guidelines for Dissertation
o Students should do literature survey and identify the problem for Dissertation and finalize in
consultation with Guide/Supervisor. Students should use multiple literatures and understand
the problem. Students should attempt solution to the problem by
analytical/simulation/experimental methods. The solution to be validated with proper
justification and compile the report in standard format.
Guidelines for Assessment of Dissertation I
o Dissertation I should be assessed based on following points
 Quality of Literature survey and Novelty in the problem
 Clarity of Problem definition and Feasibility of problem solution
 Relevance to the specialization
 Clarity of objective and scope
o Dissertation I should be assessed through a presentation by a panel of internal examiners
appointed by the Head of the Department/Institute of respective Programme.
Guidelines for Assessment of Dissertation II
o Dissertation II should be assessed based on following points
 Quality of Literature survey and Novelty in the problem
 Clarity of Problem definition and Feasibility of problem solution
 Relevance to the specialization or current Research / Industrial trends
 Clarity of objective and scope
 Quality of work attempted
 Validation of results
 Quality of Written and Oral Presentation
o Dissertation II should be assessed through a presentation jointly by Internal and External
Examiners appointed by the University of Mumbai
Students should publish at least one paper based on the work in reputed International / National
Conference (desirably in Refereed Journal)

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UNIVERSITY OF MUMBAI

Course Code Elective I Course Code Elective II

Course Teaching Credits Assigned

Course Code Elective III Course Code Elective IV

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3 NON METALS AND MANUFACTURING 08

6 Introduction to Smart / Intelligent Materials: 08

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3 Liquid Based Rapid Prototyping Systems 09

4 Solid Based Rapid Prototyping Systems 09

1. Rapid prototyping, Andreas Gebhardt, Hanser Gardener Publications, 2003.

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Die Process Quality And Automation, Die Maintenance:

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Create 3-D solid models of complex objects given a multi-view representation 08

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PDC201 PRODUCT LIFECYCLE MANAGEMENT 04

Module Detailed content Hours

4 Life Cycle Assessment and Life Cycle Cost Analysis: 08

PDC202 DESIGN FOR X 04

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5 Introduction to the concept of system design and Ergonomics

6 Introduction to basic elements of design and Ergonomics :

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2 Macromechanical Behaviour of a Lamina 08

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